Tobacco material and treatment thereof

ABSTRACT

A tobacco material and a process for the treatment of tobacco are provided. The process comprises securing the tobacco material within a moisture-retaining material and exposing the tobacco material to an ambient processing temperature of at least about 45° C., with the tobacco having a packing density of at least 200 kg/m 3  on a dry matter weight base at the start of the process and a moisture content of between about 10% and 15.5%. The treated tobacco material has an aerobic plate count of up to about 1000 CFU/g.

FIELD

The present invention relates to tobacco material and a process for thetreatment of tobacco.

BACKGROUND

After harvesting, tobacco material can be cured to prepare the leaf forconsumption. The tobacco material may be further treated, for example byaging or fermentation, to enhance the organoleptic properties of thetobacco. However, these processes can be lengthy and the quality of theresulting tobacco material can be variable. In addition, the microbialcontent or microbial composition of the tobacco material may increase oralter during these processes.

SUMMARY

According to a first aspect, a process is provided for the treatment oftobacco material wherein the treated tobacco material has an aerobicplate count of up to about 1000 CFU/g, optionally up to about 100 CFU/g,the process comprising securing tobacco material within amoisture-retaining material and exposing the tobacco material to anambient processing temperature of at least about 45° C., wherein thetobacco material has a packing density on a dry matter weight base of atleast 200 kg/m³ at the start of the process and has a moisture contentof between about 10% and 15.5% before and during treatment.

According to a second aspect, tobacco material produced according to thefirst aspect is provided.

According to a third aspect, a tobacco material secured within amoisture-retaining material is provided, wherein the tobacco materialhas been exposed to an ambient temperature of at least about 45° C., hasa packing density on a dry matter weight base of at least 200 kg/m³ anda moisture content of between about 10% and 15.5%, and wherein thetobacco material has an aerobic plate count of up to about 1000 CFU/g,optionally up to about 100 CFU/g.

According to a fourth aspect, a smoking article or a smokeless tobaccoproduct comprising the tobacco material according to the second or thirdaspects is provided.

BRIEF DESCRIPTION OF THE FIGURES

For the purposes of example only, embodiments of the invention aredescribed below with reference to the accompanying drawings, in which:

FIG. 1 shows tobacco before (left) and after (right) treatment by aprocess according to some embodiments of the invention; and

FIG. 2 is a close-up view of the tobacco shown in FIG. 1.

DETAILED DESCRIPTION

The present invention relates to a tobacco material and a process forthe treatment of tobacco material.

As used herein, the term ‘treated tobacco’ refers to tobacco that hasundergone the treatment process, and the term ‘untreated tobacco’ refersto tobacco that has not undergone the treatment process.

The treated tobacco material has an aerobic plate count (APC) of up toabout 1000 colony forming units (CFU)/g. In some embodiments, thetreated tobacco has an APC of up to about 900 CFU/g, up to about 800CFU/g, up to about 700 CFU/g, up to about 600 CFU/g, up to about 500CFU/g, up to about 400 CFU/g, up to about 300 CFU/g, up to about 200CFU/g, up to about 100 CFU/g, up to about 90 CFU/g, up to about 80CFU/g, up to about 70 CFU/g, up to about 60 CFU/g, up to about 50 CFU/g,up to about 40 CFU/g, up to about 30 CFU/g, up to about 20 CFU/g or upto about 10 CFU/g.

In some embodiments, the treated tobacco may have a low microbialcontent. As used herein, the term ‘microbial content’ refers to theamount of microorganisms present. The term ‘microbial’ may be usedinterchangeably with the term ‘microbiological’.

In some embodiments, the APC of the tobacco material may represent themicrobial content of the tobacco material. In some embodiments, an APCof up to about 1000 CFU/g may be considered to be a low microbialcontent. In some embodiments, an APC of up to about 100 CFU/g may beconsidered to be a low microbial content. In some embodiments, an APC ofup to about 20 CFU/g may be considered to be a low microbial content.

In some embodiments, the microbial content of the treated tobaccomaterial is lower than the microbial content of the untreated tobaccomaterial.

Alternatively or in addition, the treated tobacco may have a low mouldcontent. The treated tobacco may have a mould content of up to about 10CFU/g. In some embodiments, the mould content of the treated tobacco isless than 10 CFU/g, less than 8 CFU/g, less than 6 CFU/g, less than 4CFU/g or less than 2 CFU/g. The mould content of the treated tobacco maybe lower than and/or about the same level as the mould content of theuntreated tobacco material.

Alternatively or in addition, the treated tobacco may have a low yeastcontent. The treated tobacco may have a yeast content of up to about 10CFU/g. In some embodiments, the yeast content of the treated tobacco isless than 10 CFU/g, less than 8 CFU/g, less than 6 CFU/g, less than 4CFU/g or less than 2 CFU/g. The yeast content of the treated tobacco maybe lower than and/or about the same level as the yeast content of theuntreated tobacco material.

Alternatively or in addition, the treated tobacco may have a lowcoliform content. The treated tobacco may have a coliform bacteriacontent of up to about 10 CFU/g at 35° C. and/or 45° C. In someembodiments, the coliform content of the treated tobacco is less than 10CFU/g, less than 8 CFU/g, less than 6 CFU/g, less than 4 CFU/g or lessthan 2 CFU/g at 35° C. and/or 45° C. In some embodiments, the coliformcontent of the treated tobacco is o CFU/g at 35° C. and/or 45° C. Thecoliform content of the treated tobacco may be lower than and/or aboutthe same level as the coliform content of the untreated tobaccomaterial.

The low microbial, mould, yeast and/or coliform content of the treatedtobacco material may have the effect that the tobacco material is in agood physical state and/or is well preserved. The low microbial, mould,yeast and/or coliform content may minimise the occurrence of decayand/or rot in the tobacco material, thus minimising the need to discarddecayed and/or rotten tobacco material, offering considerable advantagesin terms of waste reduction and costs.

In some embodiments, the microbial composition of the treated tobaccomaterial may differ from the microbial composition of the untreatedtobacco material.

Tobacco undergoes a number of steps prior to consumption by theconsumer. On the field the following steps are usually carried out bythe farmer: seeding; transplanting; growing; harvesting; and curing.

Tobacco is generally cured after harvesting to reduce the moisturecontent of the tobacco, usually from around 80% to around 20% or lower.Tobacco can be cured in a number of different ways, including air-,fire-, flue- and sun-curing. During the curing period, the tobaccoundergoes certain chemical changes and turns from a green colour toyellow, orange or brown. The temperature, relative humidity and packingdensity are carefully controlled to try to prevent houseburn and rot,which are common problems encountered during curing. Houseburn resultsin excessive losses in dry weight resulting primarily from the action ofmicroorganisms.

At a Green Leaf Threshing (GLT) plant the tobacco is sold by the farmerand then usually undergoes the following steps: re-grading; green-leafblending; conditioning; stem removal by de-stemming or threshing (or notin the case of whole leaf); drying; and packing.

Usually after curing, the stem may be removed from the lamina. This maybe done by threshing, in which the midribs and partially the lamina ribsare separated from the lamina by machine threshing. An alternative wayto remove the stem from lamina is manually, with the so-called ‘handstripping’ process. Alternatively, tobacco may be ‘butted’, which meansthat the thick part of the stem is cut, while the rest of the tobaccoleaf remains integral.

The tobacco may be further processed to enhance its taste and aroma.Aging and fermentation are known techniques for enhancing the taste andaroma of tobacco. These processes can be applied to tobacco materialssuch as threshed lamina, hand-stripped lamina, butted lamina and/orwhole leaf tobacco.

Aging usually takes place after the tobacco has been cured, threshed (orbutted or hand-stripped) and packed. Tobaccos that undergo aging includeOriental, flue-cured and air-cured tobaccos. During aging the tobaccomight be stored generally at temperatures of around 20° C. to around 40°C. and relative humidities present at the respective country oforigin/aging or under controlled warehouse conditions for around 1 to 3years.

It is important that the moisture content of the tobacco is kept at arelatively low level during aging, for example up to around 10-13%, asmould will form in tobacco with higher moisture content.

Fermentation is a process that is applied to particular tobaccos,including dark air-cured tobacco, cured Oriental tobacco and cigartobacco, to give the tobacco a more uniform colour and to change thearoma and taste. Fermentation is generally not applied to flue-cured andlight air-cured tobacco.

The fermentation parameters, such as the moisture content of the tobaccoand the ambient conditions, vary depending on the type of tobacco thatis undergoing fermentation. Generally, the fermentation moisture iseither similar to the moisture content of the tobacco when it has beenreceived from the farmer (around 16-20%), or the tobacco is conditionedto a slightly higher moisture content. Care has to be taken to avoid theproduction of different rots, which occur when the tobacco is fermentedat a moisture content that is too high. The duration of the fermentationperiod can vary, ranging from several weeks to several years.

Generally, fermentation involves the treatment of tobacco in largevolumes and is applied to whole leaf, with subsequent removal of thestem after process. The tobacco can be arranged into large piles, whichis then turned at intervals to move the tobacco at the periphery intothe centre of the pile. Alternatively, the tobacco is placed intochambers with a volume of several square meters. Treatment of such largevolumes of tobacco can be cumbersome and/or time-consuming.

The density of the tobacco during fermentation is generally around 150to 200 kg/m³ (on a dry matter weight base). For comparison, the densityof cut rag tobacco may be as low as 70 kg/m³ and is more likely to befrom about 80 to 90 kg/m³.

Significantly, fermentation relies on the activity of microorganisms toeffect changes in the tobacco material and the fermentation conditions,including temperature and moisture content of the tobacco, are selectedto enhance the microbiological activity during fermentation. In most, ifnot all, cases the fermentation of tobacco relies upon microorganismsalready present in the tobacco material. However, suitablemicroorganisms could potentially be added to the tobacco material at thestart of the fermentation process.

After the above treatments, generally the tobacco is transported toother locations to be further processed, for example before it isincorporated into a tobacco-containing product. When the tobacco isbeing incorporated into a smoking article such as a cigarette, thetobacco is generally unpacked, conditioned, blended with other tobaccostyles and/or types and/or varieties, cut, dried, blended other tobaccomaterials, such as dry-ice-expanded-tobacco, and handed over to thecigarette manufacturing department.

Tobacco may additionally or alternatively be treated with additives toimprove or enhance the flavour and aroma of the tobacco. However, thisrequires additional processing steps and apparatus, making the tobaccopreparation process more lengthy and often more costly. In addition, itcan be desirable to have a tobacco material that has a taste and aromathat is enjoyed by consumers but has not had any additives applied to itto achieve this. This would be the case for consumers who would like anatural tobacco product that also has a pleasant flavour and/or taste,for example. Additives are generally applied in the location at whichthe smoking article is being produced, such as a cigarette factory,although the point at which additives are applied can vary.

In some embodiments, the process of treating tobacco material asdescribed herein produces a tobacco material with desirable organolepticproperties and with a low microbial content without the addition offlavour or aromatising additives.

In some embodiments, the process of treating tobacco material asdescribed herein produces a tobacco material with a low microbialcontent without the addition of substances to control and/or limitmicrobial growth in the tobacco material.

In some embodiments, the process of treating the tobacco materialpreserves the tobacco material, for example by reducing the risk ofsubsequent infestation. In some embodiments, the treated tobaccomaterial has a microbial content similar to that of tobacco materialthat has been pasteurised, but the treatment described herein is agentler and/or more natural process than conventional pasteurisationtechniques.

In some embodiments, the process of the present invention involves nofermentation or essentially no fermentation. This may be demonstrated bythe absence of microbial content of the tobacco material at the end ofthe process.

As used herein, the term ‘tobacco material’ includes any part and anyrelated by-product, such as for example the leaves or stems, of anymember of the genus Nicotiana. The tobacco material for use in thepresent invention is preferably from the species Nicotiana tabacum.

Any type, style and/or variety of tobacco may be treated. Examples oftobacco which may be used include but are not limited to Virginia,Burley, Oriental, Comum, Amarelinho and Maryland tobaccos, and blends ofany of these types. The skilled person will be aware that the treatmentof different types, styles and/or varieties will result in tobacco withdifferent organoleptic properties and/or with different TSNA contents.

The tobacco material may be pre-treated according to known practices.

The tobacco material to be treated may comprise and/or consist ofpost-curing tobacco. As used herein, the term ‘post-curing tobacco’refers to tobacco that has been cured but has not undergone any furthertreatment process to alter the taste and/or aroma of the tobaccomaterial. The post-curing tobacco may have been blended with othervarieties and types. Post-curing tobacco does not comprise or consist ofcut rag tobacco.

Alternatively or in addition, the tobacco material to be treated maycomprise and/or consist of tobacco that has been processed to a stagethat takes place at a Green Leaf Threshing (GLT) plant. This maycomprise tobacco that has been re-graded, green-leaf blended,conditioned, de-stemmed or threshed (or not in the case of whole leaf),dried and/or packed.

In some embodiments, the tobacco material comprises lamina tobaccomaterial. The tobacco may comprise between about 70% and 100% laminamaterial.

The tobacco material may comprise up to 50%, up to 60%, up to 70 %, upto 80%, up to 90%, or up to 100% lamina tobacco material. In someembodiments, the tobacco material comprises up to 100% lamina tobaccomaterial. In other words, the tobacco material may comprisesubstantially entirely or entirely lamina tobacco material.

Alternatively or in addition, the tobacco material may comprise at least50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least95% lamina tobacco material.

When the tobacco material comprises lamina tobacco material, the laminamay be in whole leaf form. In some embodiments, the tobacco materialcomprises cured whole leaf tobacco. In some embodiments, the tobaccomaterial substantially comprises cured io whole leaf tobacco. In someembodiments, the tobacco material consists essentially of cured wholeleaf tobacco. In some embodiments, the tobacco material does notcomprise cut rag tobacco.

In some embodiments, the tobacco material comprises stem tobaccomaterial. The tobacco may comprise between about 90% and 100% stemmaterial.

The tobacco material may comprise up to 50%, up to 60%, up to 70%, up to80%, up to 90%, or up to 100% stem tobacco material. In someembodiments, the tobacco material comprises up to 100% stem tobaccomaterial. In other words, the tobacco material may comprisesubstantially entirely or entirely stem tobacco material.

Alternatively or in addition, the tobacco material may comprise at least50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least95% stem tobacco material.

The moisture content of the tobacco material before and during treatmentis between about 10% and about 15.5%. As used herein, the term ‘moisturecontent’ refers to the percentage of oven volatiles present in thetobacco material.

In some embodiments, the moisture content of the tobacco is betweenabout 10% and 15.5%, optionally between about 11% and 15% or betweenabout 12% and 14%. The moisture content of the tobacco may be about 10%,about 11%, about 12%, about 13%, about 14% or about 15%.

In some embodiments, it is not necessary to redry the tobacco followingthe treatment process.

The tobacco material is secured within a moisture-retaining material, tolimit moisture losses and to retain a desired level of moisture duringthe process.

The tobacco may be completely sealed within the moisture-retainingmaterial. Alternatively, the tobacco material may not be completelysealed within the moisture-retaining material. In some embodiments, amoisture-retaining material is wrapped around the tobacco material. Insome embodiments, the tobacco material is placed within amoisture-retaining container.

The moisture-retaining material may be any material that is sufficientlyimpermeable to moisture to retain the desired amount of moisture duringthe treatment process. The amount of moisture that is retained in thetobacco material may be at least 70%, at least 75%, at least 80%, atleast 85%, at least 90%, at least 91%, at least 92%, at least 93%, atleast 94%, at least 95%, at least 96%, at least 97%, at least 98%, atleast 99%, at least 99.5% or 100% of the moisture which was present inthe tobacco material prior to treatment. In some embodiments, between99% and 100% of the moisture content of the tobacco material is retainedduring the process.

It is desirable for the moisture-retaining material to be resistant todegradation during the tobacco treatment process. For example, it isdesirable for the moisture-retaining material to withstand thetemperatures of the treatment process, without breaking down to becomemoisture-permeable or to release compounds that may be taken up by thetobacco material. The temperature reached by the tobacco material duringthe process may therefore be taken into consideration when selecting themoisture-retaining material.

The moisture-retaining material may comprise a flexible material. Thisflexible material may be wrapped around the tobacco material and/orformed into a pouch into which the tobacco is placed. In someembodiments, the moisture-retaining material comprises plastic material.In some embodiments, the moisture-retaining material comprises flexiblepolymeric material, optionally a polymeric or plastic film. In someembodiments, the moisture-retaining material comprises polyethylene. Insome embodiments, the moisture-retaining material comprises polyesters,nylon and/or polypropylene. In some embodiments, the moisture-retainingmaterial is Polyliner®. Polyliner® is available through a number ofsuppliers, including Plastrela Flexible Packaging, located in Brazil.

Alternatively or in addition, the moisture-retaining material maycomprise a rigid material, such as metal for example, which is formedinto a vessel or container. In these embodiments, a separate storagecontainer as discussed below may not be required.

In embodiments where the tobacco material reaches a temperature of about100° C. or above, the moisture-retaining material may bepressure-resistant.

The moisture-retaining material may assist in and/or affect themicrobial content and/or microbial composition of the treated tobaccomaterial. In some embodiments, the moisture-retaining material mayprevent or reduce the repopulation of the tobacco material withmicroorganisms.

At the start of the process, the tobacco material has a packing densityof at least 200 kg/m³ (on a dry matter weight base). Additionally oralternatively, at the start of the process, the tobacco material mayhave a packing density of up to about 500 kg/m³ (on a dry matter weightbase). The tobacco material may have a packing density of between about200 kg/m³ and 330 kg/m^(3,) optionally between about 220 kg/m³ and 330kg/m³. In some embodiments, the tobacco material has a packing densityof between about 260 kg/m³ and 300 kg/m³, a packing density of about 200to about 400 kg/m³, or a packing density of about 250 to about 300kg/m³.

The packing density of the tobacco material may be at least 210 kg/m³,at least 220 kg/m³, at least 230 kg/m³, at least 240 kg/m³, at least 250kg/m³, at least 260 kg/m³, at least 270 kg/m³, at least 280 kg/m³, atleast 290 kg/m³, at least 300 kg/m³, at least 310 kg/m³, at least 320kg/m³ or at least 330 kg/m³.

Alternatively or in addition, the packing density of the tobaccomaterial may be up to 220 kg/m³, up to 230 kg/m³, up to 240 kg/m³, up to250 kg/m³, up to 260 kg/m³, up to 270 kg/m³, up to 280 kg/m³, up to 290kg/m³, up to 300 kg/m³, up to 310 kg/m³, up to 320 kg/m³ or up to 330kg/m³.

The packing density of the tobacco material during and/or followingtreatment may be similar or substantially similar to the packing densityof the tobacco material at the start of the process.

The tobacco material may be placed in a storage container after it hasbeen secured within a moisture-retaining material. Placing the securedtobacco in a container enables the tobacco to be handled easily.

The volume of the storage container may be selected to achieve thedesired packing density for the desired amount of tobacco to be treated,and at the same time allows the treatment of the tobacco to take placeat a suitable rate. Alternatively or in addition, the container may beoriented on its side. This arrangement may be particularly beneficialwhen the tobacco material comprises tobacco lamina that is in ahorizontal position when placed in the storage container, as placing thestorage container on its side achieves a more even packing density.

In some embodiments, the container has a volume of between about 0.2 m³and about 1.0 m³, optionally between about 0.4 m³ and about 0.8 m³. Insome embodiments, the container has a volume of about 0.6 m³.

In some embodiments, the storage container is a case for tobacco knownas a C-48 box. The C-48 box is generally made of cardboard and hasdimensions of about 115×70×75 cm. A desirable packing density isachieved when 180-200 kg of tobacco with a moisture content of betweenabout 12 and 15% is held within a C-48 box.

The tobacco may be placed in a tobacco processing area. As used herein,the term ‘tobacco processing area’ is the area, which can be a room orchamber, in which the treatment process is carried out. The ambientprocess conditions, i.e. the conditions of the tobacco processing area,may be controlled during the process. This may be achieved by placingthe tobacco material secured within the moisture-retaining material intoa controlled environment, such as a chamber. The tobacco material may beplaced on one or more rack(s) within a chamber, to allow optimalventilation to maintain constant ambient process conditions around thetobacco. The rack(s) may have one or more shelve(s) comprising bars withgaps between the bars and/or other apertures, to assist in themaintenance of constant ambient process conditions around the tobacco.

The ambient processing humidity may be maintained at a level to avoidsignificant moisture loss from the tobacco material. As used herein, theterm ‘ambient processing humidity’ refers to the humidity of the tobaccoprocessing area. As used herein, the term ‘ambient relative processinghumidity’ refers to the relative humidity of the tobacco processingarea.

In some embodiments, the ambient relative processing humidity is about65%. The ambient relative processing humidity may be at least 40%, atleast 45%, at least 50%, at least 55%, at least 60%, at least 65% or atleast 70%.

The ambient processing temperature is at least about 45° C. In someembodiments, the ambient processing temperature is at least about 50° C.In some embodiments, the io ambient processing temperature may bemaintained at above 55° C., optionally at about 60° C. As used herein,the term ‘ambient processing temperature’ refers to the temperature ofthe tobacco processing area.

In some embodiments, the ambient processing temperature is at least 46°C., at least 47° C., at least 48° C., at least 49° C., at least 50° C.,at least 51° C., at least 52° C., at least 53° C., at least 54° C., atleast 55° C., at least 56° C., at least 57° C., at least 58° C., atleast 59° C., at least 60° C., at least 61° C., at least 62° C., atleast 63° C., at least 64° C., at least 65° C., at least 66° C., atleast 67° C., at least 68° C., at least 69° C. or at least 70° C. Insome embodiments, the ambient processing temperature is up to 60° C., upto 70° C., up to 75° C., up to 80° C., up to 85° C., up to 90° C., up to95° C., up to 100° C., up to 105° C., up to 110° C., up to 115° C. or upto 120° C.

In embodiments in which the ambient processing temperature is about 45°C., the ambient processing humidity may be about 30-70 g water/m³. Inembodiments in which the ambient processing temperature is about 55° C.,the ambient processing humidity may be about 40-80 g water/m³. Inembodiments in which the ambient processing temperature is about 60° C.,the ambient processing humidity may be about 50-110 g water/m³. Inembodiments in which the ambient processing temperature is about 70° C.,the ambient processing humidity may be about 50-160 g water/m³. Inembodiments in which the ambient processing temperature is about 80° C.,the ambient processing humidity may be about 50-230 g water/m³. Inembodiments in which the ambient processing temperature is about 90° C.,the ambient processing humidity may be about 50-340 g water/m³. Inembodiments in which the ambient processing temperature is about 100° C.or higher, the ambient processing humidity may be about 50-500 gwater/m³.

In some embodiments, the ambient processing temperature is 60° C. andthe ambient relative processing humidity is 60%.

During the process the temperature of the tobacco material reaches theambient processing temperature. The tobacco material may reach theambient processing temperature within a short period of time. Thetobacco material may reach the ambient processing temperature within 4to 10 days, optionally within 5 to 9 days, within 7 to 9 days and/orwithin 4 to 7 days.

To achieve this, the amount of tobacco treated may be optimised for theheat to be transferred to the centre of the tobacco materialsufficiently rapidly. The rate at which the temperature of the tobaccomaterial rises and reaches the ambient processing temperature will bedependent upon a number of factors, including the ambient processingtemperature, the density of the tobacco and the overall amount oftobacco being treated.

In some embodiments, the tobacco material reaches a temperature of above55° C. and/or at least 60° C. within about 9 days. In some embodiments,the tobacco material reaches a temperature of above 55° C. and/or atleast 60° C. within about 7 days. In some embodiments, the tobaccomaterial reaches a temperature of above 55° C. and/or at least 60° C.within about 5 days. In such embodiments, the ambient processingtemperature may be 60° C. In such embodiments, the tobacco may betreated in 200 kg batches.

In some embodiments, the temperature to which the tobacco material israised is at least about 55° C. or at least about 60° C. Additionally oralternatively, the temperature to which the tobacco material should beraised may be up to about 80° C., up to about 85° C., up to about 90°C., up to about 95° C., or up to about 100° C.

In some embodiments, the beneficial effects of the processing accordingto the invention may be achieved within shorter processing periods byemploying a higher ambient processing temperature.

In some embodiments, the temperature of the tobacco material may riseduring the treatment process, to reach a second temperature that ishigher than ambient processing temperature. This may be achieved withthe assistance of exothermic reactions taking place during the treatmentprocess.

In some embodiments, the tobacco material reaches a second temperaturewhich is above the ambient processing temperature. In some embodiments,the second temperature is at least 1° C. above the ambient processingtemperature, at least 2° C., at least 3° C., at least 4° C., at least 5°C., at least 7° C., at least 10° C., at least 12° C., at least 15° C.,at least 17° C. or at least 20° C. above the ambient processingtemperature. In some embodiments, the tobacco material reaches a secondtemperature which is above the ambient processing temperature withinabout 7 to 13 days, and/or the second temperature is reached withinabout 13 days or within about 11 days. In some embodiments, the tobaccomaterial reaches a second temperature of at least 5° C. above theambient temperature within about 11 to 13 days.

The temperature of the tobacco material may reach up to 60° C., up to65° C., up to 70° C., up to 75° C., up to 80° C., up to 85° C., up to90° C., up to 95° C., up to 100° C., up to 105° C., up to 110° C., up to115° C., up to 120° C., up to 125° C., up to 130° C., up to 135° C., upto 140° C., up to 145° C. or up to 150° C. during the treatment process.

Alternatively or in addition, the temperature of the tobacco materialmay reach at least 60° C., at least 65° C., at least 70° C., at least75° C., at least 80° C., at least 85° C., at least 90° C., at least 95°C., at least 100° C., at least 105° C., at least 110° C., at least 115°C., at least 120° C., at least 125° C., at least 130° C., at least 135°C., at least 140° C., at least 145° C. or at least 150° C. during thetreatment process. In practice, the upper temperature may be limited bythe thermal tolerance of the moisture-retaining material.

In some embodiments, the temperature of the tobacco material may reachbetween about 55° C. and about 90° C., between about ₅₅° C. and about80° C., or between 60° C. and about 70° C.

The tobacco may be secured within the moisture-retaining material for asufficiently long period of time for the tobacco to develop thedesirable organoleptic properties, and for a sufficiently short periodof time to not cause unwanted delay in the tobacco supply chain.

The tobacco material is secured within the moisture-retaining materialfor a period of time and at an ambient processing temperature andambient processing humidity suitable to give rise to an increase in thetemperature of the tobacco to or above a threshold temperature, whereinthe moisture content of the tobacco is between about 10% and 23%. Insome embodiments, the threshold temperature is 55° C., 60° C. or 65° C.

In some embodiments, the tobacco is secured within themoisture-retaining material for between about 5 and 65 days, for betweenabout 8 to 40 days, for between about 10 and 40 days, between about 15and 40 days, between about 20 and 40 days between about 25 and 35 daysand/or between about 28 and 32 days. The tobacco may be secured withinthe moisture-retaining material for between about 10 to 12 days. Inother embodiments, the tobacco is secured within the moisture-retainingmaterial for between about 5 and 16 days, optionally between about 6 and12 days, or between about 8 and 10 days.

In some embodiments, the tobacco is secured within themoisture-retaining material for at least 4 days, at least 5 days, atleast 6 days, at least 7 days, at least 8 days, at least 9 days, atleast 10 days, at least 11 days, at least 12 days, at least 13 days, atleast 14 days, at least 15 days, at least 16 days, at least 17 days, atleast 18 days, at least 19 days, at least 20 days, at least 21 days, atleast 22 days, at least 23 days, at least 24 days, at least 25 days, atleast 26 days, at least 27 days, at least 28 days, at least 29 days, atleast 30 days, at least 31 days, at least 32 days, at least 33 days, atleast 34 days, at least 35 days, at least 36 days, at least 37 days, atleast 38 days, at least 39 days, at least 40 days, at least 41 days, atleast 42 days, at least 43 days, at least 44 days or at least 45 days.

In some embodiments, the tobacco is secured within themoisture-retaining material for up to 5 days, up to 6 days, up to 7days, up to 8 days, up to 9 days, up to 10 days, up to 11 days, up to 12days, up to 13 days, up to 14 days, up to 15 days, up to 16 days, up to17 days, up to 18 days, up to 19 days, up to 20 days, up to 21 days, upto 22 days, up to 23 days, up to 24 days, up to 25 days, up to 26 days,up to 27 days, up to 28 days, up to 29 days, up to 30 days, up to 31days, up to 32 days, up to 33 days, up to 34 days, up to 35 days, up to36 days, up to 37 days, up to 38 days, up to 39 days, up to 40 days, upto 41 days, up to 42 days, up to 43 days, up to 44 days, up to 45 days,up to 46 days, up to 47 days, up to 48 days, up to 49 days, up to 50days, up to 51 days, up to 52 days, up to 53 days, up to 54 days, up to55 days, up to 56 days, up to 57 days, up to 58 days, up to 59 days, upto 60 days, up to 61 days, up to 62 days, up to 63 days, up to 64 daysor up to 65 days.

Embodiments in which the tobacco material reaches a higher temperaturemay require a shorter process period than embodiments in which thetobacco material reaches a lower temperature. In some embodiments, thetemperature reached by the tobacco material during the process is about5° C. above the ambient processing temperature, or between about 2 and5° C. above the ambient processing temperature and the process takesplace over a total of 25 to 35 days or a total of 20 to 30 days. Inother embodiments, the temperature reached by the tobacco materialduring the process is between about 2 and 5° C. above the ambientprocessing temperature and the process takes place over a total of 5 to16 days, a total of 6 to 15 days or a total of 8 to 12 days.

In some embodiments, the tobacco material is treated so that it is heldat the threshold temperature for a relatively short period of time. Insome embodiments, the process is halted about 6 hours, 12 hours, 18hours, 24 hours, or 2, 3, 4, 5, 6, 7 or 8 days after the temperature ofthe tobacco material reaches a threshold temperature. In someembodiments, the threshold temperature is 55° C., 60° C., or 65° C. Theperiod of time for which the tobacco material is maintained at or abovethe threshold temperature may influence the manner and extent to whichthe tobacco material is changed by the process. The thresholdtemperature may differ for different types of tobacco. The period forwhich the tobacco is maintained at or above the threshold temperaturemay differ for different types of tobacco.

In other embodiments, the tobacco material is treated so that it is heldat the threshold temperature for a longer period of time. In someembodiments, the process is halted no less than 12 days after thetemperature of the tobacco material reaches a threshold temperature. Insome embodiments, the threshold temperature is 55° C., 60° C., or 65° C.The period of time for which the tobacco material is maintained at orabove the threshold temperature may influence the manner and extent towhich the properties of the tobacco material are changed by the process.The threshold temperature may differ for different types of tobacco. Theperiod for which the tobacco is maintained at or above the thresholdtemperature may differ for different types of tobacco.

In other embodiments, the process involves treating the tobacco materialuntil the temperature of the tobacco material reaches a targettemperature, and then allowing the tobacco material to cool. Thiscooling may be effected by removing the tobacco material from theprocessing area which is being held at an elevated temperature. In someembodiments, the target temperature is 60° C., 61° C., 62° C., 63° C.,64° C., 65° C., 66° C., 67° C., 68° C., 69° C. or 70° C. In someembodiments, the target temperature is within the range of 62 to 67° C.The target temperature may differ for different types of tobacco.

In some embodiments the tobacco material is treated so that it hasdesirable organoleptic properties that are produced in a reliable wayand at relatively high volumes. In some embodiments, the process is abatch process.

In an embodiment, 180-200 kg of tobacco material with a moisture contentof 12 to 14% is wrapped in Polyliner® material and placed in a C-48carton. The C-48 carton is placed within a chamber that maintains therelative processing humidity at 60% and the ambient processingtemperature at 60° C. After a period of 5 to 9 days the temperature ofthe tobacco material reaches a temperature of about 60° C. and thencontinues to rise, to reach up a temperature of at least 5° C. above theambient processing temperature after 7 to 13 days. The tobacco materialis incubated for a total of 25 to 35 days.

After the tobacco has been incubated for the desired length of time, thetreated tobacco may be cooled down while remaining in themoisture-retaining material.

The process parameters are sufficiently gentle for the treated tobaccomaterial to maintain some or all of its physical properties. Forexample, the tobacco material remains sufficiently intact followingtreatment to allow handling and/or processing for incorporation into atobacco-containing product, such as a smoking article. This enables thetreated tobacco material to undergo handling in accordance with standardprocesses.

The treated tobacco material may have a different colour from untreatedtobacco material. In some embodiments, the tobacco material is darkerthan untreated tobacco material. This can be seen in FIGS. 1 and 2, inwhich the untreated tobacco on the left of the Figures is lighter thanthe treated tobacco on the right of the Figures.

As can be seen from Example 2 below, analysis of the treated tobaccomaterial surprisingly showed in some embodiments that the treatedtobacco material has a low or very low microbial content. This isparticularly remarkable in view of the mould and rot problems that canbe encountered in other processes in which moist tobacco is incubated,such as aging and fermentation. In Example 2 after the tobacco materialwas wrapped in a moisture-retaining material and exposed to an ambientprocessing temperature of 60° C. for 30 days, the APC was reducedsignificantly down to 20 CFU/g, the mould content was less than 10CFU/g, the yeast content was less than 10 CFU/g and no coliform CFU wereobserved at 35° C. or 45° C. All of these measurements after processingare so low that they are close to or even below the limit of detection.

In some embodiments the treated tobacco material has organolepticproperties that are acceptable and/or desirable for the consumer. Thus,tobacco material with desirable organoleptic properties can be producedby the treatment of tobacco under a specific set of conditions, andwithout requiring the addition of one or more further chemical(s), whichmay be hazardous and/or expensive. Moreover, the treated tobacco doesnot need to undergo an additional treatment step to remove the furtherchemical(s), which would add extra cost and time to the tobaccotreatment process.

The organoleptic properties of the treated tobacco material may bedeveloped when the tobacco material is secured within themoisture-retaining material, during which period the components in thetobacco material undergo chemical changes and modifications, to givedesirable organoleptic characteristics to the final product.

In some embodiments the chemical composition of the treated tobaccomaterial differs significantly from untreated tobacco material. In someembodiments the majority of the sugars in the treated tobacco materialare converted. In addition, in some embodiments the smoke generated outof the processed material incorporated into a smoking article such as acigarette contains increased levels of pyrazine and alkylpyrazines. Insome embodiments the treated tobacco material contains increased levelsof 2,5 deoxyfructosazine and 2,6 deoxyfructosazine, compared withuntreated tobacco material. The treated tobacco material may, in someembodiments, contain a reduced level of nicotine compared with untreatedtobacco material. The altered levels of these compounds may contributeto the desirable taste and aroma of the treated tobacco material.

Without being bound by theory, it is thought that the change in thelevels of at least some of these compounds is due at least in part tothe Maillard reaction taking place during the process. A caramelisationreaction may also be taking place during the process, which may lead toreduced levels of reducing and non-reducing sugars.

In addition, in some embodiments a significant decrease in the contentof various amino acids may be seen.

The production of a tobacco material with desirable organolepticproperties advantageously removes the requirement to add furthersubstances to the tobacco to provide or enhance its organolepticproperties. Such substances include flavourants and/or aromatisingingredients.

As used herein, the terms “flavour” and “flavourant” refer to materialswhich, where local regulations permit, may be used to create a desiredtaste or aroma in a product for adult consumers. They may includeextracts (e.g., licorice, hydrangea, Japanese white bark magnolia leaf,chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon,herb, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon,scotch, whiskey, spearmint, peppermint, lavender, cardamon, celery,cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, roseoil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine,ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, ora mint oil from any species of the genus Mentha), flavour enhancers,bitterness receptor site blockers, sensorial receptor site activators orstimulators, sugars and/or sugar substitutes (e.g., sucralose,acesulfame potassium, aspartame, saccharine, cyclamates, lactose,sucrose, glucose, fructose, sorbitol, or mannitol), and other additivessuch as charcoal, chlorophyll, minerals, botanicals, or breathfreshening agents. They may be imitation, synthetic or naturalingredients or blends thereof. They may be in any suitable form, forexample, oil, liquid, or powder.

The treated tobacco material may be incorporated into a smoking article.As used herein, the term ‘smoking article’ includes smokeable productssuch as cigarettes, cigars and cigarillos whether based on tobacco,tobacco derivatives, expanded tobacco, reconstituted tobacco or tobaccosubstitutes and also heat-not-burn products.

The treated tobacco material may be used for roll-your-own tobaccoand/or pipe tobacco.

The treated tobacco material may be incorporated into a smokelesstobacco product. ‘Smokeless tobacco product’ is used herein to denoteany tobacco product which is not intended for combustion. This includesany smokeless tobacco product designed to be placed in the oral cavityof a user for a limited period of time, during which there is contactbetween the user's saliva and the product.

The treated tobacco material may be blended with one or more tobaccomaterials before being incorporated into a smoking article or smokelesstobacco product or used for roll-your-own or pipe tobacco.

In some embodiments, tobacco extracts may be created from tobaccomaterial which has undergone the processing described herein. In someembodiments, the extract may be a liquid, for example it may be anaqueous extract. In other embodiments, the extract may be produced bysupercritical fluid extraction.

In some embodiments, the extracts may be used in nicotine deliverysystems such as inhalers, aerosol generation devices includinge-cigarettes, lozenges and gum. For example, the tobacco extracts may beheated to create an inhalable vapour in an electronic cigarette orsimilar device. Alternatively, the extracts may be added to tobacco oranother material for combustion in a smoking article or for heating in aheat-not-burn product.

In order to address various issues and advance the art, the entirety ofthis disclosure shows by way of illustration various embodiments inwhich the claimed invention(s) may be practiced and provide for superiortobacco treatment processes. The advantages and features of thedisclosure are of a representative sample of embodiments only, and arenot exhaustive and/or exclusive. They are presented only to assist inunderstanding and teach the claimed features. It is to be understoodthat advantages, embodiments, examples, functions, features, structures,and/or other aspects of the disclosure are not to be consideredlimitations on the disclosure as defined by the claims or limitations onequivalents to the claims, and that other embodiments may be utilisedand modifications may be made without departing from the scope and/orspirit of the disclosure. Various embodiments may suitably comprise,consist of, or consist essentially of, various combinations of thedisclosed elements, components, features, parts, steps, means, etc. Inaddition, the disclosure includes other inventions not presentlyclaimed, but which may be claimed in future.

EXAMPLES

The present invention is illustrated in greater detail by the followingspecific Examples. It is to be understood that these Examples areillustrative embodiments and that this invention is not to be limited byany of the Examples.

Example 1 Treatment of Tobacco

Virginia tobacco was green-leaf blended and threshed, conditioned andpacked in a C-48 box at 200 kg and 13% oven volatiles moisture (3 hoursat 110° C.), wrapped with polyethylene liner (Polyliner®), and was setto rest for a minimum period of 30 days before being exposed to theambient processing conditions of 60° C. and 60% relative humidity and aprocess time of 30 days.

Example 2 Analysis of Microbial Content

The microbial analysis of the treated tobacco was conducted by usingPetrifilm® Yeast and Mould Count Plates for moulds and yeasts,Petrifilm® Aerobic Count Plates for total bacteria, and the mostprobable number (MPN) method for coliforms. The results of the analysisare provided in Table 1. The results show that the microbial content ofthe treated tobacco is very low, with no coliform CFUs observed in thetreated tobacco after incubation at 35° C. or 45° C., and very lownumbers of CFUs observed for moulds and yeasts and in the aerobic platecount.

TABLE 1 Microbial analysis of tobacco before and after treatment AerobicPlate Coliforms Coliforms Count Moulds Yeasts 35° C. 45° C. Time (CFU/g)(CFU/g) (CFU/g) (CFU/g) (CFU/g) Sample 1 Before 1.80E+05 1.23E+033.33E+01 4.83E+02 non observed process Sample 2 Before 1.80E+05 9.33E+023.33E+01 6.40E+02 non observed process Sample 1 After <10* <10* <10* nonobserved non observed process (14 days) Sample 2 After 2.00E+01 <10*<10* non observed non observed process (14 days) Sample 1 After 6.66E+00<10* <10* non observed non observed process (42 days) Sample 2 After6.66E+00 <10* <10* non observed non observed process (42 days) *<10 =below detection limit

1. A process for treating tobacco material wherein the treated tobaccomaterial has an aerobic plate count of up to about 1000 CFU/g, theprocess comprising securing tobacco material within a moisture-retainingmaterial and exposing the tobacco material to an ambient processingtemperature of at least about 45° C., wherein the tobacco material has apacking density on a dry matter weight base of at least 200 kg/m³ at thestart of the process and has a moisture content of between about 10% and15.5% before and during treatment.
 2. The process according to claim 1,wherein the microbial content of the treated tobacco material is lowerthan the microbial content of untreated tobacco material.
 3. The processaccording to claim 1, wherein the tobacco material has a packing densityon a dry matter weight base of between about 200 kg/m³ and 500 kg/m³. 4.The process according to claim 1, wherein the tobacco material issecured within the moisture-retaining material for between about 5 and65 days.
 5. The process according to claim 1, wherein the tobaccomaterial is exposed to an ambient processing temperature of above 55° C.6. The process according to claim 1, wherein the tobacco material hasbeen exposed to an ambient processing temperature of at least about 45°C. or above 55° C. for at least 10 days.
 7. The process according toclaim 1, wherein the tobacco material has been exposed to an ambientprocessing temperature of at least about 45° C. or above 55° C. forbetween about 10 and 40 days.
 8. The process according to claim 6,wherein the temperature of the tobacco material reaches the ambientprocessing temperature within about 4 to 10 days.
 9. The processaccording to claim 1, wherein the ambient processing humidity is betweenabout 50-500 g water/m³ for ambient processing temperatures around orabove 100° C., about 50-340 g water/m³ for ambient processingtemperatures around 90° C., about 50-230 g water/m³ for ambientprocessing temperatures around 80° C., about 50-160 g water/m³ forambient processing temperatures around 70° C., about 50-110 g water/m³for ambient processing temperatures around 60° C., about 40-80 gwater/m³ for ambient processing temperatures around 55° C. or about30-70 g water/m³ for ambient processing temperatures around 45° C. 10.The process according to claim 1, wherein the moisture-retainingmaterial is wrapped around the tobacco material.
 11. The processaccording to claim 10, wherein the moisture-retaining material comprisesflexible polymeric material.
 12. The process according to claim 11,wherein the flexible polymeric material comprises polyethylene.
 13. Theprocess according to claim 1, wherein the tobacco material is placed ina chamber to control the ambient processing temperature and/or ambientprocessing humidity.
 14. The process according to claim 1, wherein thetobacco material comprises whole leaf tobacco.
 15. The process accordingto claim 1, wherein the tobacco material does not comprise cut ragtobacco.
 16. The process according to claim 1, wherein the tobaccomaterial is post-curing tobacco.
 17. The process according to claim 1,wherein the treated tobacco material has an aerobic plate count of up toabout 100 CFU/g.
 18. Tobacco material that has been treated according tothe process of claim
 1. 19. A tobacco material secured within amoisture-retaining material, wherein the tobacco material has beenexposed to an ambient processing temperature of at least about 45° C.,has a packing density on a dry matter weight base of at least 200 kg/m³and a moisture content of between about 10% and 15.5%, and wherein thetobacco material has an aerobic plate count of up to about 1000 CFU/g,optionally up to about 100 CFU/g.
 20. The tobacco material according toclaim 19, wherein the microbial content of the tobacco material is lowerthan the microbial content of tobacco material prior to being securedwithin a moisture-retaining material and exposed to an ambientprocessing temperature of at least about 45° C.
 21. The tobacco materialaccording to claim 19, wherein the tobacco material has been exposed toan ambient processing temperature of above 55° C.
 22. A smoking articleor a smokeless tobacco product, which comprises the tobacco material ofclaim
 19. 23. (canceled)
 24. A tobacco extract manufactured from thetobacco material of claim
 18. 25. (canceled)